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Realization of Algae Potential Algae Biomass Yield Program DOE Bioenergy Technologies Office (BETO) 2015 Project Peer Review Realization of Algae Potential Algae Biomass Yield Program March 25, 2015 Technology Area Review Peter Lammers, P.I. New Mexico State University -> Arizona State University This presentation does not contain any proprietary, confidential, or otherwise restricted information Goal Statement • Develop an integrated process for producing 2,500 gallons of bio-fuel intermediate per acre per year through radical improvements in algal areal productivity and lipid content • Successful demonstration will advance the DOE goal of producing 5,000 gallons per acre per year by 2022 • Benefits to the U.S./BETO include – Increasing the viability and deployment of renewable energy technologies – Spurring the creation of a viable domestic bio-industry – Evaluation of engineered productivity enhancements in elite strain versus an extremophile strain chosen for crop rotation purposes – Evaluation of Sequential HTL options for nutrient recycling 2 Quad Chart Overview Timeline Barriers • March 1, 2014 • Barriers addressed • Sept 30, 2016 – Feedstock supply – Conversion R&D • % Complete 40% (time) – Sustainability Budget Partners Total Costs as FY 15 Total Planned • Partners Costs of Costs Funding (FY o FY14- 12/31/14 15-Project End New Mexico State, Washington 15 Date (Non State and Arizona State Universities FFRDC) o Pan Pacific, Algenol Biofuels DOE $543K $4.265M o New Mexico Consortium Funded o National Labs: Argonne, Los NMSU/ASU $99.9K Alamos, Pacific Northwest Pan Pacific $83.2K o UOP-Honeywell (bio-crude NMC WSU $24.7K feedstock analysis) $0 *If there are multiple cost-share partners, separate rows should be used. 3 1 - Project Overview • Genetic improvements in mixotrophic algae - LANL/NMC – 40% enhancement from chlorophyll antenna size optimization – 3 fold improvement in oil content from cellobiose utilization • Horizontal photobioreactor cultivation - NMSU/ASU – EPA-exempt (40 CFR Part 725) outdoor testing of improved strains – Crop rotation for biological solution to temperature management – Calculate raceway productivity from climate simulation modeling • Sequential Hydrothermal Liquefaction - WSU/NMSU/ASU – Enables C, N and P recycle to cultivation – Cleaner fuel (less N) with bio-char used for HTL heat integration • Systems Modeling - Pan Pacific, Argonne, Algenol – LCA and TEA process models for iterative optimization of cultivation and pre-processing with mass and energy balance data – Modeling enables go/no-go decision for Phase 2 4 2 – Approach (Technical) • Key Challenges Strain stability and thermo-tolerance via strain rotation Cultivation mixing system, CO2 delivery and energy consumption Achieve harvest density of 2-3 g/L to lower harvesting costs Heat integration and intermediate separations for SEQ-HTL C, N and P recycle from HTL 5 2 – Approach (Management) • Team includes all expertise required to execute the program LANL/New Mexico Consortium – algal strain improvement NMSU/ASU – outdoor cultivation and HTL testing WSU – sequential hydrothermal liquefaction PNNL – quantitative growth modeling ANL – national leader in LCA Pan Pacific – ASPEN modeling/TEA • Two face-to-face meetings (Jan. ‘14 & ’15) • Monthly team presentations via Adobe Connect • PI Visits to WSU (July ‘14) & LANL/NMC (Feb ‘15) 6 Aspen model of REAP unit operations Aspen model of PBR cultivation for REAP process has successfully been constructed in five stages: • Stage 1- Pre-Reactor Components • Stage 2- Algal Growth • Stage 3- Downstream Processing • Stage 4- Model of SEQHTL unit operation • Stage 5- Linkage of stages for complete process model Aspen model of PBR cultivation Outcomes: • Integrated end-to-end Aspen system model for REAP process including CO2 absorption, simulations of algal growth reactors for PBR, downstream processing and SEQHTL processing. • Initial fully converged Mass and Energy balances for integrated REAP process. • Initial costing of process economics using Aspen database. 3 – Technical Accomplishments/ Progress/Results • Strain improvement - Chlorella • Cultivation trials, PBR mixing systems and CO2 delivery • Initial Sequential Hydrothermal Liquefaction Results • TEA and LCA modeling 9 Strain Selection One elite strain, one extremophile 1. C. sorokiniana strain selection – UTEX 1230, 1228 and NAABB 1412 – Genomes are only ~5% conserved – Initial genetic toolkit developed for 1230 – Thermo-tolerance 1230 > 1412 > 1228 – Productivity 1412 > 1230 – Final selection for genetic enhancements is 1412 2. G. sulphuraria - summer season strain is a low-pH extremophile, tolerant to 56oC, low lipid/high carbohydrate, versatile heterotroph 3. Strain rotation for temperature management 10 REAP pairs this cultivation approach with highly synergistic sequential hydrothermal extraction technology (SEQHTL). This is a two-stage process that: i) extracts non-lipid fractions for recycling to oil productionObjectives,; ii) converts the remaining Outcomes lipid-enriched biom assand directly Impacts to cleaner bio-fue lby interme diate with lower nitrogen content; and iii) eliminates the need for unit operations involving drying or cellular disruption. Outdoor testing of enhancePriorityd strains in Alge Areanol’s inexp ensive and scalable PBRs provides Table 1. Summary of REAP objectives, outcomes, and success criteria Improved Algal Biomass Productivity – Priority Area 1 Objectives Outcomes Impacts 1. Genetic enhancement of mixotrophic 40% increase in biomass productivity 2500 gal/acre-yr by end of 2014 Chlorella sorokiniana and 300% increase in oil content 3500 gal/acre-yr by end of 2015 2. Enclosed PBR Cultivation Systems for Outdoor PBR systems for >3 gAFDW Productivity of Greater than 25 g/m2-day EPA-exempt Outdoor Testing Enhanced per Liter autotrophic density and at Lower CAPEX and OPEX vs. Strains; Raceway Productivity Derived 6 gAFDW per Liter mixotrophic density Harmonization Model (1) from Climate-Simulation Models >50% oil content by mass Improved Pre-processing Technologies – Priority Area 2 Objectives Outcomes Impacts 3. Innovative Harvesting and Dewatering Harvested algae resulting in 5% solids; Energy Expended Less than 10% of Systems dewatering resulting in 30% solids Energy Content direct input to SEQHTL 4. Sequential Hydrothermal Extraction Continuous SEQHTL process design Technologies to Produce Bio-Fuel balancing High Efficiency Bio-Oil Cleaner Bio-Fuel Intermediate qualified Intermediate with C, N and P Recycle to Extraction and Bio-char Production for for UOP Fuel Upgrade Specifications Cultivation Heating Energy Requirement Technical Advances to Enable the Integration of the Algal Biomass Unit Operations – Priority Area 3 Objectives Outcomes Impacts 5. Physical Integration and Systems Iteratively Optimized Unit Operations for Optimum End-To-End Productivity with Modeling Algal Cultivation and Preprocessing Mass and Energy Balance Data 6. Develop LCA, TEA and Process GREET, Techno-Economic and Aspen Go Decision Triggers Engineering and Model of Integrated Process Models Enabling go/no-go Decision for Design for 1 Acre Integrated Pilot (FEL- Phase 2 2) containment in line with standards administered by EPA TSCA (40 CFR Part 725) to allow outdoor cultivation of engineered strains. The PBR approach also allows higher harvest concentrations reducing energy demand. Biochar derived from liquefaction provides the heating source for SEQHTL, thus REAP produces no co-products and minimal waste. Indeed our entire process design was driven by the need for highly compatible unit operations allowing radical improvements in biomass and bio-oil yields. The REAP collaboration includes all expertise required to execute this program. NMSU, WSU, and Algenol have expertise spanning outdoor cultivation, harvesting, and fuel intermediate production. WSU was chosen for its sequential hydrothermal liquefaction (SEQHTL) technology for the advantages presented below. The LANL team is renowned for algal strain improvement and PNNL for its quantitative growth models that underpin resource assessment. Argonne National Laboratory has world- recognized strength in life cycle analysis. Algenol has integration experience and operational experience via their algae integrated biorefinery. Pan Pacific personnel have designed, deployed, and managed industrial scale biological processes for decades and have led earlier DOE algae R&D programs. Since Pan Pacific does not produce any algae technology, it was also chosen to provide checks and balances of the technologies being developed by the various team members. Thus, Pan Pacific leads the integration effort. REAP has engaged three industrial participants (Algenol, Pan Pacific and Phycal) with large roles, in part, to ensure a culture that makes things that can get out of the lab and into the field to satisfy the Algal Biomass Yield solicitation objective of making at least 2,500 gallons of bio-fuel intermediate per acre per year by 2018. The remainder of this proposal will elaborate upon the specific approaches REAP will take, the reasons for their selection, and the management plan that will achieve the REAP objectives on time. 4/1/2013 4 Progress towards antenna size optimization Not quite there yet Strain Colonies Transgenics screened (Chl a/b ratios) Cs-1228 300 2.0 Chl a/b ratio (2.0) Cs-1230 350 3.0 Chl a/b ratio (2.3) Cs-1412 400 3.4 Chl a/b ratio (2.0) (optimum is 5) The failure to achieve higher Chl a/b ratios in Cs-1228 and Cs-1412 transgenics may reflect DNA sequence dissimilarities with the Cs-1230 CAO RNAi gene (88% identity)
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